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01-14-2020, 12:30 PM
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Join Date: Apr 2010
Location: Paris, TX
Posts: 268
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Broken Spark plug
Help....Greetings, while replacing my spark plugs today I encountered that sick feeling when one plug wouldn?t torqued down. I removed the plug to find that it had broken leaving the threaded portion of the plug in the cylinder head. Does anyone know a process to remove the broken portion from the cylinder?
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Steve Garrett - 903-272-5639, scg3037@icloud.com
N905RV - 520 hrs to date 
Home field XS30
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01-14-2020, 12:53 PM
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Join Date: Nov 2014
Location: Hinckley, Ohio
Posts: 2,704
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You will want to use a screw extractor called EZ-Out. It turns CCW and self-tightens to grasp the broken threaded barrel. You will need to measure and purchase correct size taper to fit. eBay, Amazon, or local hardware store are your friends...
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Jim Stricker - EAA #499867
PPL/ASEL 1970 - Sport Pilot since 2007
80 hrs Flying Aeronca Chief 11AC N86203
1130 hrs Flying 46 Piper J-3 Cub N6841H
Bought Flying RV-12 #120058 Oct 2015 with 48TT - Hobbs now 760 
LSRM-A Certificate 2016 for RV-12 N633CM
Special Thanks... EJ Trucks - USN Crew Chief A-4 Skyhawk
MJ Stricker (Father - CFI) - USAAF 1st Lt. Captain B-17H
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01-14-2020, 01:05 PM
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Join Date: Apr 2012
Location: Collierville, TN (KFYE)
Posts: 1,475
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You might also look at Harbor Freight. I bought a small set of screw extractors from HF just the other day.
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RV-8 #81077 Super Slow Build
Dynon Skyview HDX, Titan IOX-370, Dual P-Mags, AFP FM200A FI, Whirlwind 200RV CS Prop
First Flight 11/20/2016
https://www.marksrv8.com
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01-14-2020, 04:04 PM
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Join Date: Apr 2010
Location: Paris, TX
Posts: 268
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Thank you all for your comments and suggestions. I?ll go shopping tonight.
__________________
Steve Garrett - 903-272-5639, scg3037@icloud.com
N905RV - 520 hrs to date
Home field XS30
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01-14-2020, 06:19 PM
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Join Date: Apr 2016
Location: Bucking ham, Virginia
Posts: 284
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I'll suggest not to use a "cheap" extractor. You may use it dozens of times with great success but when it snaps off just flush or slightly below the surface you'll wish you spent 4 or 5 times that much on high quality tool such as Greenfield or Snap-On. Broken extractors and or broken taps are almost impossible to remove without damaging the part you're working on.
Might also be a good idea to heat the cylinder head with an electric heat gun to really warm it up , differential thermal expansion of the aluminum head vs. the steel portion of the broken spark plug may make the difference between success and the alternative.
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Maule MXT-7(daily flyer)
Lancer 235(partner)
Raidial RV-8R Ephanage Done, Wings Done, Fuselage on it's tall Grove gear & engine hung
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01-14-2020, 06:50 PM
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Join Date: Oct 2010
Location: Phoenix, AZ
Posts: 3,254
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A little penetrating oil may come in handy if it?s stubborn.
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01-20-2020, 06:38 PM
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Join Date: Apr 2010
Location: Paris, TX
Posts: 268
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Successful
I wanted to update this post... I was successful in removing the broken part of the spark plug with a flat blade screw driver. I got lucky this time. Thanks again to all who provided suggestions.
__________________
Steve Garrett - 903-272-5639, scg3037@icloud.com
N905RV - 520 hrs to date
Home field XS30
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01-20-2020, 07:55 PM
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Join Date: Nov 2014
Location: Hinckley, Ohio
Posts: 2,704
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Quote:
Originally Posted by Paris12Man
I wanted to update this post... I was successful in removing the broken part of the spark plug with a flat blade screw driver. I got lucky this time. Thanks again to all who provided suggestions.
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You might want to use a borescope to make sure no broken parts of the spark plug fell into the cylinder...
__________________
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Jim Stricker - EAA #499867
PPL/ASEL 1970 - Sport Pilot since 2007
80 hrs Flying Aeronca Chief 11AC N86203
1130 hrs Flying 46 Piper J-3 Cub N6841H
Bought Flying RV-12 #120058 Oct 2015 with 48TT - Hobbs now 760
LSRM-A Certificate 2016 for RV-12 N633CM
Special Thanks... EJ Trucks - USN Crew Chief A-4 Skyhawk
MJ Stricker (Father - CFI) - USAAF 1st Lt. Captain B-17H
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